Heterogeneously integrated power converter assembly

ABSTRACT

A power converter assembly is provided and includes high quality factor (Q) shield-to-transistor integrated low-inductance capacitor elements to divert common mode (CM) currents, high Q shield-to-shield integrated low-inductance capacitor elements to compliment line-to-line filter capacitors and high Q baseplate integrated low-inductance capacitor elements to attenuate residual CM currents.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. Non-provisionalPatent Application Ser. No. 16/055,792, filed Aug. 6, 2018, which claimsthe benefit of U.S. Provisional Patent Application No. 62/542,023, filedAug. 7, 2017, the disclosure of which is incorporated by referenceherein in its entirety.

FEDERAL SPONSORED RESEARCH AND DEVELOPMENT

This invention was made with government support under contract numberN00014-13-C-0231 awarded by United States Navy. The government hascertain rights in the invention.

BACKGROUND

The following description relates to a heterogeneously integrated powerconverter assembly and, more specifically, to an antenna power systemwith an integrated direct current (DC)/DC converter.

In conventional antenna power systems for radar and other similarapplications, there are typically massive numbers of off-arraysubsystems and electro-magnetic interference (EMI) filters that arerequired to achieve voltage quality. For example, a radar system caninclude a power distribution unit (PDU), an aperture power room (APR)for power conversion and distribution, multi-cable distribution and anarray antenna.

The PDU can include a 12-phase transformer that is required to provide avoltage step-down and a power factor correction (PFC) that is equal to alower total harmonic distortion (THD). The APR can include a pluralityof alternating current (AC)/DC converters that receive 12-phase 440 voltAC from the PDU. The multi-cable distribution can include a DCdistribution bus that is receptive of DC from the AC/DC converters. Thearray antenna includes multiple antenna arrays.

Each antenna array includes a number of transmit/receive integratedmicrowave module (T/RIMM) and multiple transmission/reception (T/R)channels. Each T/RIMM includes a plurality of linear regulators (one perT/R channel) and a DC/DC converter electrically interposed between theplurality of linear regulators and the DC distribution bus. The DC/DCconverter serves to provide a voltage step-down, fast dynamic loadresponse in T/R operations and reduces voltage ripples and noise. Eachlinear regulator provides for fast response and low noise point of load(POL) voltage. Each T/R channel is responsible for T/R operations andincludes a power amplifier and a modulator electrically interposedbetween the power amplifier and a corresponding one of the linearregulators.

BRIEF DESCRIPTION

According to an aspect of the disclosure, a power converter assembly isprovided and includes high quality factor (Q) shield-to-transistorintegrated low-inductance capacitor elements to divert common mode (CM)currents, high Q shield-to-shield integrated low-inductance capacitorelements to compliment line-to-line filter capacitors and high Qbaseplate integrated low-inductance capacitor elements to attenuateresidual CM currents.

In accordance with additional or alternative embodiments, the powerconverter assembly is provided as a galvanically-isolated bridgeconverter.

According to another aspect of the disclosure, an integrated converterof an antenna power system is provided and includes a baseplate and atransformer area interposed between input and output sections. Thetransformer area includes a magnetic core top portion, a magnetic corebottom portion disposed on the baseplate, a magnetic core pillarextending between central sections of the magnetic core top and bottomportions and successive layers of shield and magnetic core materials,windings and magnetic core materials and shield and magnetic corematerials interleaved between dielectric material layers at oppositesides of the magnetic core pillar.

In accordance with additional or alternative embodiments, the integratedconverter is provided as a galvanically-isolated bridge converter.

In accordance with additional or alternative embodiments, the shieldmaterials include metallic materials.

In accordance with additional or alternative embodiments, the magneticcore top and bottom portions have similar widths, the magnetic corepillar has a lesser width than the magnetic core top and bottomportions, and the successive layers of the windings and the magneticcore materials extend outwardly to respective edges of the magnetic coretop and bottom portions.

In accordance with additional or alternative embodiments, the successivelayers include primary winding materials, first and second primaryshield materials above and below the primary winding materials,secondary winding materials and first and second secondary shieldmaterials above and below the secondary winding materials.

In accordance with additional or alternative embodiments, the first andsecond primary shield materials extend continuously into the transformerarea from the input section and the first and second secondary shieldmaterials extend continuously into the transformer area from the outputsection.

In accordance with additional or alternative embodiments, the first andsecond primary shield materials discontinuously correspond to shieldmaterials in the output section and the first and second secondaryshield materials discontinuously correspond to shield materials in theinput section.

In accordance with additional or alternative embodiments, the magneticcore materials in each successive layer of shield and magnetic corematerials form a C-shape or a reverse C-shape about the magnetic corepillar.

According to another aspect of the disclosure, an antenna power systemis provided and includes an alternating current (AC)/direct current (DC)converter, which is receptive of AC, a common bus, which is receptive ofDC from the AC/DC converter and a plurality of transmission/reception(T/R) channels coupled to the common bus. Each T/R channel includes apower amplification assembly and a discrete input capacitor electricallyinterposed between the common bus and the power amplification assembly.The power amplification assembly includes a discrete output capacitorelectrically interposed between a power amplifier and an integratedDC/DC converter comprising shields extending into a transformer area.

In accordance with additional or alternative embodiments, the integratedDC/DC converter is provided as a galvanically-isolated bridge converter.

In accordance with additional or alternative embodiments, thetransformer area of the integrated DC/DC converter is interposed betweenan input section including the discrete input capacitor and an outputsection including the discrete output capacitor.

In accordance with additional or alternative embodiments, thetransformer area of the integrated DC/DC converter includes a magneticcore top portion, a magnetic core bottom portion disposed on abaseplate, a magnetic core pillar extending between central sections ofthe magnetic core top and bottom portions and successive layers ofshield and magnetic core materials, windings and magnetic core materialsand shield and magnetic core materials interleaved between dielectricmaterial layers at opposite sides of the magnetic core pillar.

In accordance with additional or alternative embodiments, the shieldmaterials include metallic materials.

In accordance with additional or alternative embodiments, the magneticcore top and bottom portions have similar widths, the magnetic corepillar has a lesser width than the magnetic core top and bottom portionsand the successive layers of the windings and the magnetic corematerials extend outwardly to respective edges of the magnetic core topand bottom portions.

In accordance with additional or alternative embodiments, the successivelayers include primary winding materials, first and second primaryshield materials above and below the primary winding materials,secondary winding materials and first and second secondary shieldmaterials above and below the secondary winding materials.

In accordance with additional or alternative embodiments, the first andsecond primary shield materials extend continuously into the transformerarea from the discrete input capacitor and the first and secondsecondary shield materials extend continuously into the transformer areafrom the discrete output capacitor.

In accordance with additional or alternative embodiments, the first andsecond primary shield materials discontinuously correspond to shieldmaterials in the discrete output capacitor and the first and secondsecondary shield materials discontinuously correspond to shieldmaterials in the discrete input capacitor.

In accordance with additional or alternative embodiments, the magneticcore materials in each successive layer of shield and magnetic corematerials form a C-shape or a reverse C-shape about the magnetic corepillar.

According to another aspect of the disclosure, a method of forming anintegrated direct current (DC)/DC converter is provided. The methodincludes laying down, in an input section, first and second layers ofinterleaved input section shield materials with layers of dielectricmaterials interleaved between the first and second layers of interleavedinput section shield materials. The method also includes laying down, inan output section, first and second layers of interleaved output sectionshield materials with layers of dielectric materials interleaved betweenthe first and second layers of interleaved output section shieldmaterials, assembling, in a transformer area between the input andoutput sections, a magnetic core pillar between top and bottom magneticcore portions and interleaving, in the transformer area, layers ofdielectric materials with layers of magnetic core materials withwindings, extensions of the first layers of input section shieldmaterials or extensions of second layers of output section shieldmaterials.

In accordance with additional or alternative embodiments, the methodfurther includes laying down the magnetic core materials in C— andreverse C-shapes about the magnetic core pillar in the layers ofmagnetic core materials with windings, extensions of the first layers ofinput section shield materials or extensions of second layers of outputsection shield materials.

These and other advantages and features will become more apparent fromthe following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter, which is regarded as the disclosure, is particularlypointed out and distinctly claimed in the claims at the conclusion ofthe specification. The foregoing and other features, and advantages ofthe disclosure are apparent from the following detailed descriptiontaken in conjunction with the accompanying drawings in which:

FIG. 1 is a schematic diagram of an antenna array power system inaccordance with embodiments;

FIG. 2A is a side view of an integrated DC/DC power converter for use inthe antenna array power system of FIG. 1;

FIG. 2B is an enlarged side view of a transformer area of the integratedDC/DC power converter of FIG. 2A;

FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 2A;

FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 2A;

FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 2A; and

FIG. 6 is a cross-sectional view taken along line 6-6 of FIG. 2A;

These and other advantages and features will become more apparent fromthe following description taken in conjunction with the drawings.

DETAILED DESCRIPTION

As will be described below, an architecture for an antenna array powersystem is provided with T/R module or channel-based DC/DC converters.This leads to a system that is simplified relative to conventionalsystems and universal T/RIMM elements that provide for greaterportability when certain voltages (e.g., 300 VDC) are available from acommon source. The architecture is characterized in that most of itspower conversion components are disposed in the antenna array, whichleads to a smaller, lighter and a higher performance and low cost systemoverall.

In typical power conversion systems, common mode (CM) currents aregenerated by switching transitions and are coupled to an equipmentground by parasitic capacitance. At a load, the CM currents areconverted into differential-mode ripples and noise. Meanwhile,differential (i.e., line-to-line) filters do not attenuate CM currentsand an effectiveness of dedicated CM filters can be limited because CMcurrents often have wide ranges and high frequencies of up to hundredsof megahertz. Thus, it is often difficult to suppress CM currentswithout adding substantial electro-magnetic interference (EMI)filtering.

In the presently claimed invention, however, high quality factor (Q)shield-to-transistor integrated low-inductance capacitor elements serveto divert CM currents, high Q shield-to-shield integrated low-inductancecapacitor elements serve to compliment line-to-line filter capacitorsand high Q baseplate integrated low-inductance capacitor elements serveto attenuate residual CM currents. This is achieved by integratedelectrostatic shields being disposed to extend into a transformer areato contain CM currents by providing for low-inductance internal paths,the presence of “hybrid” magnetic cores that include discrete (“bulk”)and integrated components to reduce magnetic reluctance and straymagnetic fields as well as composite dielectric layers that have low E,high Q dielectrics windings of magnetics and high E dielectrics forlayers outside of the magnetics to reduce relative volumes of discretecapacitors.

With reference to FIG. 1, an antenna power system 100 is provided. Theantenna power system 100 includes an AC/DC converter 101 that isreceptive of AC, a common DC distribution bus 102 that is receptive ofDC from the AC/DC converter 101 and a plurality of T/R channels 110.Each T/R channel 110 is responsible for T/R operations and includes apower amplification assembly 111 and a discrete input capacitor 112. Thediscrete input capacitor 112 is electrically interposed between thecommon DC distribution bus 102 and the power amplification assembly 111.The power amplification assembly 111 includes a discrete outputcapacitor 113, which is electrically interposed between a poweramplifier 114 and an integrated DC/DC converter 115. The integratedDC/DC converter 115 may be provided as a galvanically-isolated bridgeconverter and includes shields extending into a transformer area as willbe described below.

With reference to FIGS. 2A and 2B, components of the integrated DC/DCconverter 115 are illustrated. As shown in FIG. 2A, the integrated DC/DCconverter 115 includes a transformer area 120 that is interposed betweenan input section 130 and an output section 140. The input section 130includes the discrete input capacitor 112 and the output section 140includes the discrete output capacitor 113. The transformer area 120includes a magnetic core top portion 121 that is formed of magneticmaterials, a magnetic core bottom portion 122 that is disposed on abaseplate 123 and is formed of magnetic materials, a magnetic corepillar 124 that extends between central sections of the magnetic coretop and bottom portions 121 and 122 and successive layers 125 atopposite sides of the magnetic core pillar 124. The successive layers125 include layers of shield (i.e., metallic) and magnetic corematerials, layers of windings and magnetic core materials and layers ofshield and magnetic core materials, each of which are interleavedbetween dielectric material layers 126.

In accordance with embodiments, the magnetic core top and bottomportions 121 and 122 have similar widths, the magnetic core pillar 124has a lesser width than the magnetic core top and bottom portions 121and 122 and the successive layers 125 of the windings and the magneticcore materials extend outwardly to respective edges of the magnetic coretop and bottom portions 121 and 122.

As shown in FIG. 2B, the successive layers 125 include a layer ofprimary winding materials 150 and magnetic core materials 151 as well asa layer of first primary shield materials 152 and magnetic corematerials 153 above the layer of the primary winding materials 150 andthe magnetic core materials 151 and a layer of second primary shieldmaterials 154 and magnetic core materials 155 below the layer of theprimary winding materials 150 and the magnetic core materials 151. Inaddition, the successive layers 125 include a layer of secondary windingmaterials 156 and magnetic core materials 157 as well as a layer offirst secondary shield materials 158 and magnetic core materials 159above the layer of the secondary winding materials 156 and the magneticcore materials 157 and a layer of second secondary shield materials 160and magnetic core materials 161 below the layer of the secondary windingmaterials 156 and the magnetic core materials 157.

The layers of the first and second primary shield materials 152 and 154extend continuously into the transformer area 120 from the discreteinput capacitor 112 of the input section 130 and discontinuouslycorrespond to layers of additional shield materials 162 (see FIG. 2A) ofthe discrete output capacitor 113 in the output section 140. The layersof the first and second secondary shield materials 158 and 160 extendcontinuously into the transformer area 120 from the discrete outputcapacitor 113 of the output section 140 and discontinuously correspondto layers of additional shield materials 163 (see FIG. 2A) of thediscrete input capacitor 112 in the input section 130.

With reference to FIG. 3, in the layer of the first primary shieldmaterials 152 and the magnetic core materials 153 above the layer of theprimary winding materials 150 and the magnetic core materials 151, themagnetic core materials 153 form a reverse C-shape about the magneticcore pillar 124. In addition, the magnetic core materials 153 aresurrounded by dielectric materials 1530 and are adjacent to a line ofdielectric materials 1531. The line of dielectric materials 1531separates the first primary shield materials 152 from the layers of theadditional shield materials 162. The layer of the second primary shieldmaterials 154 and the magnetic core materials 155 below the layer of theprimary winding materials 150 and the magnetic core materials 151 aresimilarly formed.

With reference to FIG. 4, in the layer of the primary winding materials150 and the magnetic core materials 151, the magnetic core materials 151form a reverse C-shape about the magnetic core pillar 124. In addition,the magnetic core materials 151 are surrounded by dielectric materials1510 and are adjacent to a line of dielectric materials 1511. The lineof dielectric materials 1511 separates input capacitor shield materials164 from output capacitor shield materials 165 (see FIG. 2A).

With reference to FIG. 5, in the layer of the first secondary shieldmaterials 158 and the magnetic core materials 159 above the layer of thesecondary winding materials 156 and the magnetic core materials 157, themagnetic core materials 159 form a C-shape about the magnetic corepillar 124. In addition, the magnetic core materials 159 are surroundedby dielectric materials 1590 and are adjacent to a line of dielectricmaterials 1591. The line of dielectric materials 1591 separates thefirst secondary shield materials 158 from the layers of the additionalshield materials 163. The layer of the second secondary shield materials160 and the magnetic core materials 161 below the layer of the secondarywinding materials 156 and the magnetic core materials 157 are similarlyformed.

With reference to FIG. 6, in the layer of the secondary windingmaterials 156 and the magnetic core materials 157, the magnetic corematerials 157 form a C-shape about the magnetic core pillar 124. Inaddition, the magnetic core materials 157 are surrounded by dielectricmaterials 1570 and are adjacent to a line of dielectric materials 1571.The line of dielectric materials 1571 separates output capacitor shieldmaterials 166 from input capacitor shield materials 167 (see FIG. 2A).

The output capacitor shield materials 165 may be similar materials asthose of the layers of the first and second secondary shield materials158 and 160. Similarly, the input capacitor shield materials 167 may besimilar materials as those of the layers of the first and second primaryshield materials 152 and 154.

In accordance with embodiment, all of the layers of the primary andsecondary shield materials can occupy a same volume on separate layersonly in the transformer area 120. This serves to reduce transformerfeed-through capacitance (i.e., primary shields do not cross over to thesecondary side and vice versa). In addition, layers of shield materialsthat are referenced to a highest DC voltage (either primary orsecondary) may be extended under the transformer area 120.

While the disclosure is provided in detail in connection with only alimited number of embodiments, it should be readily understood that thedisclosure is not limited to such disclosed embodiments. Rather, thedisclosure can be modified to incorporate any number of variations,alterations, substitutions or equivalent arrangements not heretoforedescribed, but which are commensurate with the spirit and scope of thedisclosure. Additionally, while various embodiments of the disclosurehave been described, it is to be understood that the exemplaryembodiment(s) may include only some of the described exemplary aspects.Accordingly, the disclosure is not to be seen as limited by theforegoing description, but is only limited by the scope of the appendedclaims.

What is claimed is:
 1. An antenna power system, comprising: analternating current (AC)/direct current (DC) converter, which isreceptive of AC; a common bus, which is receptive of DC from the AC/DCconverter; a plurality of transmission/reception (T/R) channels coupledto the common bus, each T/R channel comprising: a power amplificationassembly; and a discrete input capacitor electrically interposed betweenthe common bus and the power amplification assembly, the poweramplification assembly comprising a discrete output capacitorelectrically interposed between a power amplifier and an integratedDC/DC converter comprising shields extending into a transformer area,wherein the transformer area comprises magnetic core top and bottomportions, a magnetic core pillar extending between the magnetic core topand bottom portions and successive layers of shield and magnetic corematerials, windings and magnetic core materials and shield and magneticcore materials interleaved between dielectric material layers atopposite sides of the magnetic core pillar.
 2. The antenna power systemaccording to claim 1, wherein the integrated DC/DC converter is providedas a galvanically-isolated bridge converter.
 3. The antenna power systemaccording to claim 1, wherein the transformer area of the integratedDC/DC converter is interposed between an input section comprising thediscrete input capacitor and an output section comprising the discreteoutput capacitor.
 4. The antenna power system according to claim 1,wherein: the magnetic core bottom portion is disposed on a baseplate,and the magnetic core pillar extends between central sections of themagnetic core top and bottom portions.
 5. The antenna power systemaccording to claim 1, wherein the shield materials comprise metallicmaterials.
 6. The antenna power system according to claim 1, wherein:the magnetic core top and bottom portions have same widths, the magneticcore pillar has a lesser width than the magnetic core top and bottomportions, and the successive layers of the windings and the magneticcore materials extend outwardly to respective edges of the magnetic coretop and bottom portions.
 7. The antenna power system according to claim1, wherein the successive layers comprise: primary winding materials;first and second primary shield materials above and below the primarywinding materials; secondary winding materials; and first and secondsecondary shield materials above and below the secondary windingmaterials.
 8. The antenna power system according to claim 7, wherein:the first and second primary shield materials extend continuously intothe transformer area from the discrete input capacitor, and the firstand second secondary shield materials extend continuously into thetransformer area from the discrete output capacitor.
 9. The antennapower system according to claim 7, wherein: the first and second primaryshield materials discontinuously correspond to shield materials in thediscrete output capacitor, and the first and second secondary shieldmaterials discontinuously correspond to shield materials in the discreteinput capacitor.
 10. The antenna power system according to claim 1,wherein the magnetic core materials in each successive layer of shieldand magnetic core materials form a C-shape or a reverse C-shape aboutthe magnetic core pillar.
 11. An antenna power system, comprising: aplurality of transmission/reception (T/R) channels, each T/R channelcomprising: a power amplification assembly; and a discrete inputcapacitor electrically interposed between a common bus and the poweramplification assembly, the power amplification assembly comprising adiscrete output capacitor electrically interposed between a poweramplifier and an integrated converter comprising shields extending intoa transformer area, wherein the transformer area comprises magnetic coretop and bottom portions, a magnetic core pillar extending between themagnetic core top and bottom portions and successive layers of shieldand magnetic core materials, windings and magnetic core materials andshield and magnetic core materials interleaved between dielectricmaterial layers at opposite sides of the magnetic core pillar.
 12. Theantenna power system according to claim 11, wherein the integratedconverter comprises a galvanically-isolated bridge converter.
 13. Theantenna power system according to claim 11, wherein the transformer areais interposed between an input section comprising the discrete inputcapacitor and an output section comprising the discrete outputcapacitor.
 14. The antenna power system according to claim 11, wherein:the magnetic core bottom portion is disposed on a baseplate, and themagnetic core pillar extends between central sections of the magneticcore top and bottom portions.
 15. The antenna power system according toclaim 11, wherein the shield materials comprise metallic materials. 16.The antenna power system according to claim 11, wherein: the magneticcore top and bottom portions have same widths, the magnetic core pillarhas a lesser width than the magnetic core top and bottom portions, andthe successive layers of the windings and the magnetic core materialsextend outwardly to respective edges of the magnetic core top and bottomportions.
 17. The antenna power system according to claim 11, whereinthe successive layers comprise: primary winding materials; first andsecond primary shield materials above and below the primary windingmaterials; secondary winding materials; and first and second secondaryshield materials above and below the secondary winding materials. 18.The antenna power system according to claim 17, wherein: the first andsecond primary shield materials extend continuously into the transformerarea from the discrete input capacitor, and the first and secondsecondary shield materials extend continuously into the transformer areafrom the discrete output capacitor.
 19. The antenna power systemaccording to claim 17, wherein: the first and second primary shieldmaterials discontinuously correspond to shield materials in the discreteoutput capacitor, and the first and second secondary shield materialsdiscontinuously correspond to shield materials in the discrete inputcapacitor.
 20. The antenna power system according to claim 11, whereinthe magnetic core materials in each successive layer of shield andmagnetic core materials form a C-shape or a reverse C-shape about themagnetic core pillar.